Insulating Panel for Stucco Exterior

ABSTRACT

An exterior wall cladding system for application to an exterior wall surface comprises a sealed and laminated waterproof wrap applied to the exterior wall surface, a fully-sealed insulating panel without a drainage plane disposed over the sealed and laminated waterproof wrap. The cladding system and method provide a waterproof wall structure for a multi-layer stucco coating applied over the insulating panel. Sealing materials are applied to all openings through and edges of the wall structure.

CROSS REFERENCE TO RELATED APPLICATIONS

This Application is a continuation of U.S. patent application Ser. No. 15/654,188, filed Jul. 19, 2017 and entitled EXTERIOR WALL CLADDING SYSTEM AND FOR BUILDINGS, filed by the same inventor and claims priority to U.S. Provisional Patent Application Ser. No. 62/463,354 filed Feb. 24, 2017 and entitled STUCCO SYSTEM, filed by the same inventor. This application is related to copending application by the same inventor and entitled METHOD OF WATERPROOFING ROOFS AND BUILDING PANELS, which is a Continuation-In-Part of U.S. patent application Ser. No. 15/654,188.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention generally relates to the construction of building exteriors and more particularly to a system and method for constructing a cladded exterior wall of a building such as a stucco exterior wall to seal the wall and prevent damage from the ingress of water and insects into the structure of the exterior wall.

2. Background of the Invention and Description of the Prior Art

The exterior walls of residential and commercial buildings are clad with a variety of materials and construction. Apart from structural considerations, the cladded exterior walls of such buildings must withstand all sorts of weather, in a wide-ranging gamut of temperatures, water and other forms of precipitation, wind, solar radiation, and other meteorological conditions. Other considerations include resistance to damage by insects and other animals or by plants and trees. In addition, to conserve energy it is crucial that such walls be well insulated against the transmission of heat through the walls.

In a typical building, for example, a wood-framed residential house, the wood framework is covered with a wall sheathing secured to the wood framework. Such exterior wall sheathing may be wood panels or composite wood-based or felt or pressed-fiber panels, sometimes covered with a heavy paper or moisture barrier. The outside surface of the exterior walls may then be covered or clad with siding materials of wood, metal, or synthetic materials; brick or stone work; or a stucco wall system.

In a conventional process, stucco is a composition of aggregates, water, and a binder that is prepared and applied as a thick liquid or slurry to a surface, usually in several coats, and allowed to harden into a dense, hard surface that is generally durable and weather-resistant. The aggregate material is typically lime, although sand, synthetic aggregates, glass fibers, or Portland cement are commonly used. The wall surface to which the stucco mixture is applied is generally prepared by installing lath—a type of lattice or wire mesh to support the wet mixture as it hardens.

While stucco is a versatile material, that also lends itself to many decorative treatments, it is brittle and its long term durability depends substantially on the skill of the craftsman employed to apply it. It is susceptible to cracking as a building structure settles, flexes with movement of the earth, similarly to gypsum wall board, etc. Thus, unless openings in the stucco coating are properly finished, particularly along the top and bottom edges, around pass-through fixtures for plumbing or electrical lines, windows and doors, etc., the integrity of a stucco exterior may be seriously weakened. Moreover, one commonly used construction technique requires formation of a drainage plane between the exterior wall and the insulating panel (or the stucco layers if no insulating panel is used). An example of this system is the so-called Exterior Insulation and Finish System or “EIFS.”

The EIFS structure requires a drainage plane formed by vertical passages on the back side of insulating panels that are included between the exterior wall and the stucco layers. The drainage plane provides passages in a thin space between the exterior wall sheathing and an insulating panel, either with grooves formed in the back side of the insulating panel or by troweling vertical paths in the adhesive layer that is used to secure the insulating panel to the exterior wall surface. The passages thus provided theoretically allow drainage of water that may find its way inside the wall so that it does not accumulate and cause damage to the wall (e.g., rot) or accumulation of fungal substances (e.g., “mold”). However, unless the EIFS structure is properly installed, the symptoms of water condensation or accumulation in the thin drainage plane spaces, or insect (e.g., termite) damage, or even mold contamination may go unnoticed—often for years—until the damage is so severe that the wall must be entirely removed and replaced to repair the damage. Accordingly, the formation of the drainage plane, and the long-term durability of the EIFS structure depends critically on the proper formation of the thin space between the exterior wall and the insulating panel of stucco. For example, if the space is too thin, water may become trapped in the space due to surface forces. Or, if the drainage spaces formed by troweling are not all vertically-oriented, water may become trapped within the non-vertical portions of the drainage spaces.

Thus, in balance, stucco exterior walls, whether constructed according to conventional methods or the EIFS method, are susceptible to substantial damage due to water originating generally from weather events. Such events provide numerous and varied opportunities for water to enter and become trapped in the interstices of an exterior wall, especially stucco exterior walls. Experience with repairing damage to stucco-clad exterior walls demonstrates that it is not enough to (1) install a stucco exterior wall surface by conventional methods without limiting opportunities for water to find its way into the stucco structure through openings, cracks or other defects. It is not enough to (2) use a finish coat of flexible acrylic—as is sometimes recommended—to cover the exterior so that when cracks develop they are “bridged” by the flexible coating. It is not sufficient to (3) include drainage planes that provide thin spaces for moisture to condense or collect and that are sensitive to the process technique(s) required to install them properly. It is not enough to (4) provide a weep screed at the lower edge of the stucco wall if that portion of the wall is susceptible of pooling water or the screed is improperly installed.

There is thus a need for a system and method for constructing exterior wall cladding, including stucco finishes, which provides a wall that is thoroughly waterproof, does not allow the ingress of water or moisture, and is able to withstand all kinds of contacts with water in any form without loss of integrity or durability.

SUMMARY OF THE INVENTION

A wall cladding system for application to an exterior wall surface comprises a sealed waterproof wrap applied to the exterior wall surface; a fully-sealed insulating panel without a drainage plane disposed over the laminated waterproof wrap; and a multi-layer stucco coating applied to the insulating panel.

In one aspect the sealed waterproof wrap comprises a coat of silicone elastomeric (SE) roof coating; an L-shaped flashing formed of anti-fracturing fiber cloth (AFF cloth) attached to the lower edge of the coated exterior wall surface; a wrap of AFF cloth covering to seal all openings in the exterior wall surface; and the SE roof coating applied to the covered openings.

In another aspect the fully sealed insulating panel without drainage plane comprises an insulating panel without drainage plane grooves, coated with the SE roof coating on its back side and disposed against the sealed waterproof wrap applied to the exterior wall surface and secured with basket screws. The insulating panel further comprises a plurality of closed cell EPS foam sheets joined edge-to-edge, each having dimensions of 3 feet×5 feet and a thickness between one inch and three inches; wherein the edge-to-edge joints are sealed using the AFF and the SE roof coating. Window and door openings may be trimmed to an outward facing angle and sealed with the AFF cloth and the SE roof coating; and utility openings and basket screws sealed with the AFF cloth and the SE roof coating. In addition, the outward facing angle is approximately 45 degrees.

In another aspect the multi-layer stucco coating applied to the insulating panel includes a weep screed disposed to terminate the lower edge of the stucco wall; and a sealed top flashing along the upper edge of the stucco exterior wall. In this aspect the multi-layer stucco coating may comprise a base coat of Portland cement, type I-H mixed with a cement adhesive, plus a layer of glass fiber screen embedded therein; a first and a second coat of a synthetic stucco coating; and a finish coat of the SE coating.

In another aspect the sealed top flashing comprises a metal or plastic plate configured to disperse water outward away from the exterior wall surface.

In another aspect a curb footing formed of concrete secured and sealed to a foundation structure of the building and against the outer side of the exterior wall surface. In this aspect the curb may comprise a rebar frame secured to the foundation structure with embedded lag screws; a concrete curb footing formed over the rebar frame; and a weep screed attached to the sealed waterproof wrap of the coated exterior wall surface at the lower edge thereof and disposed over the curb footing.

In another embodiment, a stucco exterior wall system is disclosed, comprising an exterior wall framed and erected on a foundation and sheathed with a sheathing of wood, fiber, or synthetic panel material; a laminated and sealed waterproof wrap applied to the surface of the exterior wall, and further including a coat of a silicone elastomeric (SE) roof coating, an anti-fracturing fabric (AFF) taped or wrapped and sealed around all openings, and an L-shaped flashing of AFF applied at the foot of the exterior wall at the intersection of the wrapped wall surface and the foundation; and a fully-sealed insulating panel having no drainage plane or surface voids and installed over the laminated and sealed waterproof wrap, wherein the insulating panel is coated with the SE roof coating on the back thereof, and placed against the wrapped wall, and secured with basket screws sealed with silicone caulk inserted in a pilot hole provided for the basket screws; wherein window and door openings are cut at an outward facing angle of approximately 45 degrees outward, sealed with AFF and the SE roof coating and utility openings are sealed with AFF and the SE roof coating; a multi-layer stucco coating applied to the insulating panel, including a first stucco coat, a fiberglass mesh strip disposed against a lower edge of the insulating panel, a second stucco coat, and a coat of the SE coating as a finish coat to the stucco coating; and a top flashing is installed over a wrap of AFF and the SE roof coating disposed along the upper edge of the stucco exterior wall.

In another aspect, a concrete curb may be installed on the foundation at the foot of the exterior wall, including a rebar frame secured to the foundation, the concrete curb formed against the exterior wall over the rebar frame, and a weep screed attached to the laminated and sealed waterproof wrap and disposed against the foot of the exterior wall over the curb.

In another embodiment, a waterproof, insulated structural panel is disclosed for attaching to a building frame for an exterior stucco wall erected on a foundation, comprising a rigid sheathing attached to an exterior side of the building frame; and an insulating panel, supplied without drainage grooves, applied to the rigid sheathing using a bonding structure applied to the sheathing side of the insulating panel; wherein the insulated structural panel is characterized by the absence of any interlayer spaces or voids between the insulating panel and the sheathing and a sealing composition applied to any penetration or passage through the insulated structural panel.

In another aspect, the bonding structure comprises a first coat of a liquid silicone elastomeric roof coating applied to the outer side of the sheathing a strip of an anti-fracture fabric formed into an L-shape flashing, a first side disposed against the foot of the sheathing and a second side disposed against the foundation; and a second coat of the silicone elastomeric roof coating applied to the sheathing and the first side of the L-shaped flashing.

In another aspect, the insulating panel comprises an expanded polystyrene foam sheet having a defined thickness, width, and length, and a rated insulating “R” value; wherein both sides of the sheet are free of drainage grooves or other features forming a drainage plane having surface voids.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a simplified perspective view of a residential building wall erected on a slab foundation;

FIG. 2 illustrates a simplified end view of one embodiment of the wall structure of FIG. 1 according to the present invention;

FIG. 3 illustrates an elevation cross section view of the wall structure of FIG. 2 depicting the inner layers of the present invention;

FIG. 4 illustrates an elevation cross section view of the wall structure of FIG. 3 depicting the addition of an insulating board over the inner layers;

FIG. 5 illustrates an elevation cross section view of the wall structure of FIG. 4 depicting the outer layers of the present invention; and

FIG. 6 illustrates a simplified perspective view of a three-part wall system according to the present invention to depict sealing treatment of passages through the wall such as windows and utility conduits.

DETAILED DESCRIPTION OF THE INVENTION Introduction

The invention to be described herein provides an advance in the state of the art, an improved exterior wall cladding system that solves the problems noted in the Background of the Invention herein. These problems with conventional stucco exterior walls are summarized as follows. It is not enough to (1) install a stucco exterior wall surface by conventional methods without limiting opportunities for water to find its way into the stucco structure through openings, cracks or other defects. It is not enough to (2) use a finish coat of flexible acrylic—as is sometimes recommended—to cover the exterior so that when cracks develop they are “bridged” by the flexible coating. It is not sufficient to (3) include drainage planes that are sensitive to the process technique(s) required to install them properly. It is not enough to (4) provide a weep screed at the lower edge of the stucco wall if that portion of the wall is susceptible of pooling water or the screed is improperly installed.

Each of the four problems with stucco wall cladding enumerated in the previous paragraph may be the source of substantial water damage if the conventional installation techniques and remedies are not properly installed or constructed. Many if not all of these problems arise for at least one or two—and sometimes both—of the following reasons. One, failure to properly seal all possible openings where moisture can enter the wall system; and two, the inclusion in a wall or panel structure of space where water can condense or accumulate. Some of the construction techniques developed to deal with these problems include the use of metal flashing strips at joints between roofs and walls, around openings such as doors and windows, and at the lower edges of wall cladding. Often these flashing strips are augmented by caulking applied to seal any gaps that may remain after the metal flashing is installed. Another construction design is to provide features that encourage drainage of moisture from within a wall system, either by providing clear vertical passages in the space between layers of the wall system, and a variant of flashing called a weep screed at the bottom edge of a wall cladding intended to provide a draining surface for moisture that may exist within the layers of a wall cladding.

During rehabilitation of exterior walls of buildings heavily damaged by water that found its way inside wall systems through unsealed openings and accumulated because there was no efficient drainage, these and other problems suggested the need to rethink the entire process of how exterior walls are constructed and clad with the surfaces to protect the walls and provide attractive appearance. The first key insight was to realize that providing or allowing spacing or voids between the layers of an exterior wall is an invitation to water damage. The second key insight was to realize that failure to seal all possible openings between the interior and exterior of a building against water ingress, even though the wall system is not a stucco wall that is conventionally installed with a drainage plane within the wall, is also an invitation to water damage. Water damage to an exterior wall system may go unnoticed for many years, leading to failure of the wall, rotting of wood or other materials, accumulation of mold that is often a hazard to the health of the building occupants. Moreover, unsealed openings can permit infestation by insects or even other small animals, bringing potential health hazzards to the building occupants and structural damage such as caused by termites.

The solution to both kinds of problems was to eliminate any spaces or voids within the wall system of a building—or even a roof system—where water can condense or accumulate (and insects can enter and thrive), and to fully seal and waterproof all openings in and through the wall system. The methods described herein are illustrated by application to construction of a stucco wall system but the techniques are applicable to any type of wall system or structural panel. The methods employ several synthetic materials and the replacement of some metal flashing materials as sealing elements with a wrap and coat process using synthetic materials. Metal flashing, while suitable for some sealing applications, oxidizes and corrodes over time, which degrades the sealing capabilities of the material, no matter how carefully installed. Caulking materials eventually lose their sealing capability, especially when exposed to climate conditions outside the wall that leads to cracking, hardening, and failure of the original sealing effect. Some felt paper under-layments deteriorate over time and lack the ability to seal the surface upon which they are applied. The use of nails, screws, and other fasteners that puncture a cladding material provide opportunities for water to enter. Even some screws and nails, though plated or coated, can degrade or loosen over time, leading to leaks unless properly sealed using techniques to be described herein. Unless these edges, joints, openings, and puncture points are well-sealed with suitable materials, liquid substances, primarily water will find its way in beneath the layers of the wall structure, allowing the process of rotting of the sub-surfaces to begin and weakening the integrity of the wall, panel, or roof cladding.

Solutions to these problems, which are featured in the present invention and disclosed herein are, respectively: (A) the exterior wall in all respects must be sealed against water from the exterior wall surface outward, including the top and bottom of the wall. (B) More than a simple outer coat of flexible acrylic is required to fully waterproof an exterior wall system, including walls finished with stucco cladding. (C) The simplest way to overcome the problems with drainage planes and other voids is to eliminate them and provide a solid structure that both prevents water from entering the stucco wall structure and eliminates interstitial spaces where water or moisture can accumulate. (D) The weep screed, in addition to proper installation must be supplemented with sealing, either by judicious use of sealing materials or installation of a substantial barrier to moisture ingress at the lower edge of the stucco exterior wall system. These solutions, when implemented with sufficient skill and with synthetic materials carefully selected (but widely available) result in long term durability of the stucco and other cladded wall systems because the opportunities for water to enter the wall are eliminated. Further, the use of synthetic materials that have some inherent resilience improves the ability of the finished wall system to resist cracking over time. This novel combination of features, which runs counter to industry-accepted methods, such as the EIFS system, provides a stucco exterior wall system that solves the aforementioned problems. Moreover, elimination of the drainage plane is an essential feature of the invention because the stucco exterior wall system described herein is designed to keep water from ever entering the stucco wall structure. Providing internal spaces for draining water is thus unnecessary and redundant and, when provided may degrade the wall system as described.

DETAILED DESCRIPTION

FIG. 1 illustrates a simplified perspective view of a residential building wall 10 erected on a foundation such as a concrete slab, a pier and beam foundation, a foundation structure constructed of wood and or steel structural members, or other suitable base structure. FIGS. 2 through 6 and the accompanying description illustrate one embodiment of a method and system of constructing an improved exterior wall cladding system 20 on a concrete slab foundation, including, for example, a stucco-cladded exterior wall system 20 according to the present invention. Reference numbers appearing in more than one figure identify the same features.

The following list of materials are used in the construction of the exemplary exterior wall cladding system 20 described herein. Some of the materials are available from more than one source. The items in the list are provided as examples of materials that are suitable for use in constructing the present invention. In one case, the Portland Cement and the Foam & Mesh Adhesive and Base Coat are mixed before use: ½ bag (94 lb.) Portland Cement to 2½ gallons of the Adhesive and Base Coat. This will be called a “cement/adhesive mixture” in the following description.

Silicone Elastomeric (SE) “GacoElastomeric” roof coating, two gallon pails—Gaco Western, Waukesha, Wis. 53186.

Anti-fracture Fabric (AFF), 6″×75′ rolls—Laticrete International, Inc., Bethany, Conn. 06524.

Expanded Polystyrene (EPS) closed-cell foam, 1½″ to 2½″ thick, 3′×5′ sheets, no drainage grooves—available from several manufacturers.

Portland Cement, Type I-II, 47 or 94 lb. bags—Sakrete, Inc., Charlotte, N.C.

Cement Adhesive, “F&M Foam & Mesh Adhesive and Base Coat,” pails—Master Wall, Inc., Midland, Ga. 31808.

Synthetic Stucco Coatings, specified as “DPR Finishes”—Dryvit Systems, Inc., West Warwick, R.I. 02893.

Fiberglass Mesh Drywall Tape, 4.5 oz/sq·yd., 36″×150′ rolls—PrimeSource Building Products, Inc., Irving, Tex.

Weep Screed with ⅝″ lift—Niles Building Products Company, Niles, Ohio.

In FIG. 1, a structure formed of studs 18, sole plate 14 and top plate 16, and sheathing 22 form a basic building wall 10 erected on a slab foundation 12. As noted above, the foundation 12 may be constructed in a variety of ways, depending on the characteristics of the building site and the style or type of structure to be erected. The sheathing 22 may be plywood or OSB (oriented strand board) panels, gypsum board, fiberboard, rigid foam panels, or diagonal 1″×6″ (or 1″×8″) boards applied to the framework 14, 16, 18 constructed of wood or metal products on the foundation 12.

FIG. 2 illustrates a simplified end elevation view of one embodiment of the exterior wall cladding system 20 based on the building wall 10 of FIG. 1 according to the present invention. The exterior wall cladding system 20 may also be called the wall structure 20 or the wall system 20 in the description that follows. The view in FIG. 2 depicts the combination of sheathing 22, inner layers 24, an intermediate insulation layer 60, and outer layers 26 that together form the complete structure of the exterior wall cladding system 20, including the outer stucco finish 28 of the wall system 20. As will be described, all layers 24, 60, and 26 preferably include substantial amounts of sealing involved in their application.

Continuing with FIG. 2, the exterior wall cladding system 20 may include a curb 36 installed at the junction of portions of the inner layers 24 and the foundation 12. This curb 36 will be described in FIGS. 3 and 4. Shown in FIG. 2 is a layer of fiberglass mesh screen 72 (to be described further in FIG. 5) that is wrapped over the top of the wall structure 20 and disposed within the outer layer 26 of the wall structure 20. Upon completion of all layers of the wall structure, including the fiberglass mesh screen 72, a top flashing 92 is installed on the top of the wall structure 20 and secured with screws 94 after coating the top of the wall structure 20 with a liquid silicone elastomeric (SE) 90 (aka SE roof coating herein). The top flashing 92 is typically disposed under the roof (not shown) adjoining the wall structure 20.

FIG. 3 illustrates an elevation cross section view of the wall structure of FIG. 2 depicting the inner layers 24 of the present invention. This figure primarily depicts the inner layers 24 and the optional curb 36 and related structures. The inner layers 24 are formed as a composite of several layers of material applied in sequence. (1) A coat 30 of SE roof coating on the sheathing 22 from top of the wall to the foundation 12 and extending approximately 8 inches from the foot of the wall; (2) an L-shaped section 32 of AFF applied over the coat 30 on the foot of the wall and extending along both the vertical and horizontal directions approximately 5 inches from the foot of the wall; and (3) a second coat 34 of the SE roof coating applied over the first coat 30 and the AFF “L” section 32. These two coats of the SE roof coating material and the intervening AFF form a waterproof wrap covering the sheathing and provide a base for attaching the intermediate insulating layer 60 to be described with FIG. 4. The silicone elastomeric (SE) roof coating in this application may also be known and used as a liquid elastomeric seal. In addition (4) a weep screed 44 is attached to the wall sheathing 22 with flat head screws 46 with the angled edge of the weep screed 44 disposed approximately 5″ to 6″ above the foundation 12; and (5) a layer of fiberglass mesh 48 is applied to the wall 20 from the top to the angle formed in the weep screed 44 and secured to the wall 20 with staples 50. An extension of the lower edge of the fiberglass mesh 48 of approximately 12 inches is provided, to be secured later in the sequence when installing the intermediate insulating layer 60. In the foregoing process, it is preferred that the flat head screws 46 and the staples 50 are installed so that they are flush with the surfaces they secure to the wall 20, as shown in FIG. 3. In addition, it is essential that the SE roof coating be applied generously in the region where the weep screed 44, the AFF reinforcing layer 48, and the SE coating 62 on the back side of the insulating board 60 are in close proximity.

In some applications the foundation 12 is formed in a way that permits water to accumulate near the foot of the wall, thereby forming a shallow pool that may find its way through imperfect sealing at the bottom or foot of the wall. To provide a barrier to such water an optional curb 36 may be constructed of Portland Cement—Type I & II to prevent water leaking through the foot of the wall 20. If the optional curb 36 is to be used, it should be fabricated after the AFF section 32 and the second coat 34 of SE roof coating are applied as shown in FIG. 3. It is necessary to first construct a reinforcing structure formed of reinforcing bar (rebar) 38 supported on standoffs 40 embedded into the foundation 12. The standoffs 38 may alternatively be driven or screwed into the wall 20. The rebar 38 may be secured to the standoffs 40 using wire 42. After the reinforcing structure 38,40,42 is installed, forms (not shown) to shape the curb 36 may be placed along the foot of the wall 20. In general the outward facing side of the curb 36 should slope downward and away from the wall 20 as shown to provide drainage.

FIG. 4 illustrates an elevation cross section view of the wall structure of FIG. 3 depicting the addition of an intermediate insulating layer 60 comprising an insulating board disposed over the inner layers 24. The insulating board 60 may preferably be a panel formed of a plurality of closed-cell, expanded polystyrene (“EPS”) foam sheets, available from a variety of manufacturers. The EPS is generally available in sheets or panels 3 feet wide by 5 feet long, and thicknesses between 1 inch and 3 inches thick. In the present example, the closed cell EPS panels are 1½ inches thick, providing an R value of approximately 6.9. It is important that both sides of the sheets be uniformly smooth and free of openings, voids, grooves or other surface irregularities that could retain moisture. This includes EPS or other synthetic foam panels having a drainage plane—grooves in the surface of the panel—preformed on one side—i.e., the back side to be placed against a wall surface. In the present invention, panels of insulating material with such drainage planes are not acceptable. The present invention provides a cladded exterior wall that has no spaces within any of its layers or coatings or any unsealed openings through any of the layers. In other words the completed cladded exterior wall is a solid structure.

Installation of the insulating panels 60 proceeds as follows. First, the panels 60 are prepared by slightly roughening the surface of the side to be placed in contact with the fiberglass mesh 48. The purpose of the roughening step is to ensure a suitable surface for the silicone elastomeric roof coating, used as an adhesive, to bond well to the surface of the EPS insulating panel. After the roughening step, a coating 62 of the SE material is applied as an adhesive. This coating, which fills any irregularities in the surface that occurred during the roughening step, is called the “back-side coating” 62. Next, the panels of the insulating board 60 are positioned edge-to-edge against the layer of fiberglass mesh 48 previously applied, to cover the entire wall 20. Then the insulating board 60 may preferably be secured to the wall 20 using so-called “basket screws” 64, driven through the inner layers 24 into the sheathing 22. It is essential that pilot holes (not shown) for each basket screw 64 be pre-drilled through the insulating board 60, the inner layers 24, and into the sheathing 22. The pilot holes are then filled with a silicone caulking compound (a 40 year grade—not shown). Four to six basket screws per panel are preferred to secure the insulating panels 60 against the wall 20, primarily while the SE coating cures, to ensure a firm, sealed bond to the wall 20. The “basket screws” are equipped with enlarged flat metal washers to retain the heads from penetrating the EPS foam panels 60. Finally, the lower edge 66 of the fiberglass mesh 48 should be coated with a layer of SE (not shown), wrapped under the lower edge of the insulating board 60, and attached to the outward face of the lower edge of the insulating board. Cut-out openings for windows or utility access may be provided as needed. Such openings must be formed and sealed as will be described with FIG. 6.

FIG. 5 illustrates an elevation cross section view of the wall structure of FIG. 4 depicting the outer layers 26 of the present invention. The outer layers 26 include a reinforced base coat plus the stucco layers of the exterior wall cladding system, thus providing a multi-layer stucco coating. The reinforced base coat is applied to support the stucco layers against the insulating board 60. The reinforced base coat includes a first coat 70 of a mixture of Portland Cement and Cement Adhesive (“PC/CA,” or “cement/adhesive”), a layer of fiberglass mesh 72 that is preferably pressed into the first coat 70, and a second coat 74 of the PC/CA or cement/adhesive. It should be noted that the fiberglass mesh layer 72 must be wrapped upward and over the top of the wall 20 as shown to provide the best support for the PC/CA layers to be described. The Portland Cement and Cement Adhesive mixture used in the first 70 and second 74 coats is mixed as follows: one 94 lb. bag of Portland Cement with five gallons of the Cement Adhesive, or ½ of a 94 lb. bag of Portland Cement with 2½ gallons of the Cement Adhesive. A prescribed amount of time must be allowed after the fiberglass mesh layer 72 is applied for the first PC/CA coat 70 to set and cure before the second PC/CA coat 74 is applied. The second coat 74 must also be allowed sufficient time for the mixture to cure before subsequent steps are performed.

When the second PC/CA coat 74 is fully cured, at least one and preferably two synthetic stucco coatings are applied over the second PC/CA coat 74. The first and second coats 76, 78 of the synthetic stucco material—the Dryvit “DPR Finish” synthetic stucco coating—is the preferred material. These DPR Finish synthetic stucco coatings are available in various colors and are designed to withstand a wide range of weather conditions without cracking or deterioration. Finally, a finish coat 80 of the SE roof coating may be applied as a sealing coat to ensure that rain and moisture is easily shed.

FIG. 6 illustrates a simplified perspective view of a three-part wall system according to the present invention to depict sealing treatment of passages through the wall such as windows, doors, and utility access conduits. The wall system 100 includes the sheathing (22) and inner (24) layers 110, the insulating board (60)—layer 122 including the adjoining coatings—and the stucco outer (26) layers 114. The three sections of the wall 100 are joined at first 116 and second 118 corners as shown. The corners 116, 118 may be reinforced with flashing strips 150, 152 respectively as shown by the dashed lines in FIG. 6. These flashing strips 150, 152, which may be made of metal or thermoplastic material, typically 6″×6″ on each side of the angle, and may be applied after the insulating layer (60) 122 is installed. The flashing strips 150, 152 should be coated with SE coating and attached with screws inserted into pilot holes filled with caulking compound as described for the basket screws 64 as shown in FIG. 4. It should be pointed out that these uses of caulking compound to fill pilot holes are not exposed to the outside; rather these uses of caulking material are internal and sealed behind coats or layers of material.

A first exterior side 102 is depicted with a window opening 120 that is surrounded by a beveled frame 122. The beveled frame 122 may be formed by cutting through the outer layers 26 of the first exterior side 102 to produce an outward facing angle of approximately 45 degrees in this example. After smoothing the cut portions, a layer of AFF drywall tape may be applied, followed by one or more coats of the SE roof coating. The purpose of the 45 degree angle is to allow rain water to drain from the window 120.

Similarly, the second exterior side 104 is depicted with an opening housing an outlet box 130 for providing a receptacle (not shown) for connecting to the electrical wiring of the building or a switch (not shown) for the control of an electrical circuit. The outlet box 130, set into the wall 104, may likewise be surrounded by an angled frame 132 that is formed of AFF drywall tape and sealed with the SE roof coating. As shown in the third exterior side 106, a water faucet 140 is mounted in an opening through the side 106. The opening is preferably wrapped with AFF drywall tape and sealed with the SE roof coating. These three examples illustrated in FIG. 6 depict the concept of wrap and seal that must be applied to all openings or passages through the exterior wall 100. These examples are not exhaustive; in fact persons skilled in the art will readily understand how the illustrated technique can be adapted to seal any opening in the wall 20.

Returning to FIG. 2, the side elevation view of a cross section of a completed wall structure that is cladded according to the present invention. The view of the wall structure 20 in FIG. 2 depicts the combination of sheathing 22, inner layers 24, an intermediate insulation layer 60, and outer layers 26 that together form the complete structure of the exterior wall cladding system 20, including the outer stucco finish 28 of the wall system 20. As has been described, all layers 24, 60, and 26 preferably include substantial amounts of sealing to ensure that no water or other forms of moisture can enter or pass through the wall structure 20. Upon completion of all layers of the wall structure 20, including the fiberglass mesh screen 72, the top flashing 92 is installed on the top of the wall structure 20 and secured with screws 94 after coating the top of the wall structure 20 with the liquid silicone elastomeric (SE) 90. The top flashing 92 is typically disposed under the roof (not shown) adjoining the wall structure 20.

The structure and process for cladding of an exterior wall as described herein provides an improved stucco exterior wall, according to one embodiment of the present invention, is similar to a conventional stucco wall with several important differences: (1) the drainage plane and any other internal voids are eliminated, and (2) all surfaces and openings/pass-throughs are sealed or secured to each other using combinations of a silicone elastomer (SE) roofing coating and an anti-fracturing fiber cloth (AFF cloth). The fabric materials are used as a sheet covering or as a tape to cover openings through the insulation panel such as utility passages, windows, doorways, etc., as has been described. The silicone elastomer (SE) roof coating is applied as a liquid to seal joints in the materials used. Other sealing components may be used to seal and protect corners and the base of the exterior wall where the stucco exterior is adjacent the building foundation. These differences form the departure in the state of the art provided by the present invention.

It has been found while installing the exemplary stucco exterior wall system described herein that the process is actually more efficient and faster because of the ease with which the liquid silicone elastomeric (SE) coating material can be applied. Although designed for covering roofs, particularly flat roofs, the SE roof coating material is ideally suited for the construction techniques described herein because of its durability, and its adhesive and sealing properties. Elimination of the drainage plane, especially the type formed by troweling or scratching the cement or other coating before application of the insulating layer (in the case of an EIFS system), eliminates a time-consuming task—a task that is often improperly done because of the time needed to perform it correctly—and one that when carelessly formed, can lead to major water damage and necessary reconstruction of the stucco exterior. Such reconstruction is even more expensive and time-consuming than the initial construction of the stucco exterior wall.

CONCLUSION

While the invention has been shown in only one of its forms, it is not thus limited but is susceptible to various changes and modifications without departing from the spirit thereof. In the broadest sense, the invention is a waterproofing system for composite, layered panels used in buildings or any structure including vehicles, trucks, shipping containers, etc. where it is important to provide wall structures impervious to water and weather.

For example, various alternative but equivalent materials or mechanisms for sealing openings may be used as long as the integrity of the seal is maintained, and the materials and methods are capable of providing effective sealing for up to several decades. Further, the exterior wall cladding system described herein is compatible with various types of foundations and flooring structures. In another example, in addition to a foundation constructed with a concrete floor, indoor or outdoor flooring or decking constructed of tiles or wood products (or synthetic equivalents thereof), flooring configured with artificial turf, or just concrete flooring coated with a silicone elastomeric roof coating, with or without some sort of aggregate such as pebbles or crushed rock, etc.

The exterior wall cladding system is also compatible with various outer veneers or wall coverings such as brick, stone, wood or synthetic siding materials, or even roofing materials applied instead of stucco finishes. The system may also be used on curved wall surfaces by using sheathing and insulating board techniques to provide the needed curvature.

Persons skilled in the art will recognize that certain steps in the process described herein must allow sufficient time for the materials to set, dry, or cure before succeeding steps are carried out. The required time will depend on local weather, temperature, and seasonal conditions. Also to be noted is that the silicone elastomeric roof coating is used as both an adhesive and a membrane in the disclosed wall cladding system. Similarly, the anti-fracture fabric drywall tape is used as a reinforcing layer, a wrap around components that penetrate the wall system, or as flashing strips. Further, the use of synthetic materials are virtually impervious to insects as long as all openings are fully sealed.

Persons skilled in the art will also recognize that the principles of the concepts described herein are readily applicable to waterproofing most composite layered panels used in buildings and vehicles. In other words, whenever it is necessary to configure panels of buildings and vehicles (in particular trucks, shipping containers, railroad cars, etc.) with waterproof cladding such as walls, floors, ceilings, roofs and the like so that they are substantially impervious to water or leaks of water through the panels, the system and methods described herein provide durable, economical solutions to waterproofing such panels. Other examples of building surfaces that may be waterproofed using the teachings of the present invention include shower stalls or tiled walls or floors where the tile surface is applied in place of the stucco coatings. 

What is claimed is:
 1. A method of constructing an insulated, waterproofed exterior wall of a building to receive a stucco finish, comprising the steps of: installing panels of sheathing on exterior framework of the building; preparing the sheathing to receive an insulating panel by applying a waterproof wrap of first and second coats of a silicone elastomeric (SE) roof coating to the sheathing; forming a flashing of fabric having a first edge disposed along a lower edge of the first coat of SE roof coating and a second edge disposed along the foundation, followed by a second coat of the SE roof coating applied to the sheathing and the first edge of the flashing; attaching a weep screed to the sheathing, proximately above the first edge of the flashing; roughening a smooth side of the insulating panel, formed of sheets of expanded polystyrene (EPS) closed cell foam, to receive a third coat of the SE roof coating; applying the third coat of SE roof coating to the roughened side of the insulating panel; pressing the coated insulating panel sheets against the coated sheathing, in edge-to-edge relationship, while the third coat of SE roof coating is still wet; and sealing any openings through and edge seams of the insulating panel with an inner coat of the SE roof coating, a covering of fabric, and an outer coat of Se roof coating; wherein the combination of the waterproof wrap, the insulating panel, the third coat of SE roof coating, and the sealed openings forms a solid, insulated wall covering that is free of interior spaces and gaps and fully sealed against water.
 2. The method of claim 1, further comprising the step of: if the ambient temperature is less than 50 degrees Fahrenheit, securing the insulating panel sheets against the prepared sheathing with approximately four basket head screws installed in pilot holes filled with 40-year-rated silicone exterior caulking compound.
 3. The method of claim 1, further comprising the step of: applying the first and second coats of the SE roof coating as a liquid.
 4. The method of claim 1, further comprising the step of: forming the fabric flashing of anti-fracture fabric (AFF) material in strips approximately six inches wide and folded lengthwise.
 5. The method of claim 1, further comprising the step of: forming the fabric wrap for covering any openings of anti-fracture fabric (AFF) material; and sealing the formed AFF material with a coat of the SE roof coating.
 6. The method of claim 1, wherein the step of pressing the coated insulating panel sheets against the coated sheathing further comprises the steps of: covering the seams along adjoining edges of the sheets with a coat of SE roof coating; and covering the coated seams with a strip of anti-fracture fabric (AFF) material.
 7. The method of claim 1, wherein the expanded polystyrene (EPS) closed cell foam has no drainage plane or surface voids on either side.
 8. A waterproof insulating panel for use between a waterproofed exterior sheathing and an exterior stucco cladding of a building, comprising: a plurality of insulating panel sheets of expanded polystyrene (EPS) closed cell foam, each sheet having a back side and a front side wherein each sheet is characterized by a smooth surface on at least one side thereof; each sheet is prepared by roughening the side having the smooth surface and coating the roughened side with a first, liquid coat of silicone elastomeric (SE) roof coating; the coated side of each sheet is pressed against the sheathing, joining edge-to-edge at a seam to cover the sheathing while the first, liquid coat of SE roof coating is still wet; each seam is covered by a strip of anti-fracture fabric (AFF) bonded to the seam on the front side with a strip of SE roof coating applied along the seam; and a second coat of SE roof coating is applied to the front side of the plurality of sheets; wherein the combination of the insulating panel coated on both sides with SE roof coating and the sealed openings forms a solid, insulated wall covering that is free of interior spaces and gaps and fully sealed against water.
 9. The waterproof insulating panel of claim 9, comprising: a waterproof wrap formed of anti-fracture fabric (AFF) around and over openings for passage of utilities and air ducts through the insulating panel sheets.
 10. The waterproof insulating panel of claim 8, comprising: a waterproof wrap formed of anti-fracture fabric (AFF) around frames for windows and doorways through the insulating panel sheets.
 11. The waterproof insulating panel of claim 8, wherein: if the ambient temperature is less than 50 degrees Fahrenheit, securing the insulating panel sheets against the prepared sheathing with approximately four basket head screws installed in pilot holes filled with 40-year-rated silicone exterior caulking compound.
 12. The waterproof insulating panel of claim 8, wherein the sheets of expanded polystyrene (EPS) closed cell foam have no drainage plane or surface voids on either side.
 13. The waterproof insulating panel of claim 8, wherein: the combination of the insulating panel coated on both sides with SE roof coating and the sealed openings forms a solid, insulated wall covering having some inherent flexibility to provide resistance to cracking. 